NDM Rapid Tooling Process for Aluminum and Thermoplastic

NDM Rapid Tooling Process for Aluminum and Thermoplastic Parts Paul Armstrong John Mathews

NDM Process • Patented program – Owned & licensed by B&D Sales Corporation • Under development for several years – Continuing R&D for improvement • Armstrong Mold and B&D Sales working jointly to: – Increase the number of applications – Expand industries that can utilize this procedure

Topics • • • Benefits of NDM Design considerations Process steps Case study Where do we go from here? ?

Benefits of NDM

Core and Cavity • Process yields excellent tool finish • Captures intricate detail

Core in Universal Base • 600, 000 shots and still running

Cavity • Ideal for geometrically complex shapes

Benefits • Versatility – Die casting – Thermoplastic injection molding – MIM (metal injection molding) • Fast turnaround, low cost – 2 weeks from CAD file to part • Mold hardness – Extended tool life • Quick cavity duplication – Ideal for multi-cavity molds

Design Considerations • Cavity/Core insert size – 1” x 1” to 4” x 6” x 2” • Complex angular/curvaceous shapes • Part materials – Aluminum – Most thermoplastics – Most MIM materials • Draft angles – Industry standards with radii and fillets

Design Considerations • Wall thickness – Die casting industry standards – Injection molding industry standards • Tool life – Prototype quantities to 100, 000+

Process Comparison : Injection Molded Plastics Lead Time (Wks) Tool Life Cost Heat Transfer Cavity Finish M/C AL 4 -5 Fair Low Excel. Good M/C Prehard 5 -6 Good Med Good M/C Hardened 6 -7 Excel. High Good Excel. Cast AL 3 -4 Fair Low Excel. Good Cast Kirksite 3 -4 Fair Low Excel. Good NDM Excel. Low Excel. 2 -3

Process Comparison: Metal Die Casting Lead Time (wks) Tool Life Cost Heat Cavity Transfer Finish M/C Prehard 5 -6 Good Med Excel. Good M/C Hardened 6 -7 Excel. High Excel. NDM 2 -3 Excel. ? Low Excel.

NDM Process Steps

Step 1 – Engineering Review • Prep of e-model – Add shrink – Add draft

Step 2 – Build Pattern • Create master model – SLA – CAM

Step 3 – Rubber Mold • Create pattern – Negative impression from master – Using RTV

Step 4 – Prepare Mold • Treat rubber mold with mold release

Step 5 - Fill Mold • RTV molds filled • Stainless steel powder • Proprietary binder

Step 6 - Baking • Green work piece is baked • Removes liquid binder

Step 7 – Furnace Cycle • Work piece is heated in vacuum furnace • Burns off binder

Step 8 - Infiltration • Infiltrate with bronze to full density

Step 9 – Prep Inserts • • • Finish inserts and prep for mold base Rig mold Load into die cast machine

Step 10 - Run Parts • Cavity mounted in mold base

Step 10 - Run Parts • Core with ejector pins out • Note gates and runners

Step 11 - Finish part • Raw casting with runner still attached

Step 11 - Finish part • Casting – both sides • Runner now removed • Part ready for de-flash

Step 12 - Finished Part • Finished part –Machined in tight tolerance features –Satin Nickel Chrome Plating • <. 001” thick

Case Study - Camera Housing • Initial prototyping – SLA – CNC hogouts • DFM analysis – Improved casting design • RPM casting – Initial 20 prototypes – Aluminum (functional)

Case Study - Camera Housing • Product development refinement cycle – 3 revisions – Samples via RPM • Bridge to production – RPM for 4000 parts • RPM cost – Tooling: $5, 000 – Casting: $19. 85 each

Case Study- Camera Housing • CAD to usable die-cast parts – NDM in only 4 weeks • NDM cost – Die: $12, 000 – Casting: $3. 30 each • Tool payback/breakeven – 725 pieces • Ramp up – RPM: 100 per week per tool set – NDM: 1, 000’s per week

Where do we go from here? • Larger parts • Faster turnaround • Compete with off shore and others for production applications

Where do we go from here –Apply to other processes • MIM-Metal Injection Molds • Thermoplastic Injection Molds • Investment wax tools

Injection Molded Plastic • Plastic- Noryl 873

MIM- Metal Injection Molding • Nickel/ Steel Alloy

Questions www. armstrongmold. com Paul Armstrong - sales@armstrongmold. com John Mathews - jmathews@armstrongmold. com

To Obtain Information Regarding The Licensing of The NDM Process Contact: B&D Sales Corporation 19 Fifth Avenue Cranston, RI 02910 sales@bdsales. com 401 -781 -4810 Fax: 401 -781 -5580